Cleaning article

ABSTRACT

There is disclosed a cleaning article including a brush portion. The brush portion has a plurality of strips and at least one layer of a fiber bundle.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a disposable cleaning article to beheld by a holder and used as a cleaning mop or by a hand and, moreparticularly, to a cleaning article provided with a brush portion havinga high effect to trap dust and a high rigidity.

2. Related Art

In the cleaning article of the conventional mop type for cleaning theroom, its brush portion is usually formed of twisted yarns of cotton orthe like. However, the cleaning article of this kind is so expensive inmanufacturing cost that it is difficult to sold it as a disposable(i.e., single-use) product. In addition, the cleaning article of thiskind can absorb dust by an adhesive oil agent such as liquid paraffin,which is applied to the surfaces of the twisted yarns; but the twistedyarns per se are not good in dust trapping power. Therefore, it has adefect in capability of trapping hair or the like.

On the other hand, the cleaning articles as disclosed in JapaneseUnexamined Patent Publication Nos. 154791/1997 and 38009/1997 aredesigned for disposable use. These cleaning articles can be attached toa holder. The former is formed by laminating two sheets of nonwovenfabric to leave their peripheral portions unadhered to each other; andthe latter is formed by cutting a peripheral portion of a nonwovenfabric to form a duster portion having long narrow strips.

These cleaning articles, as disclosed in the above-mentioned officialgazettes and formed of a nonwoven fabric, are inexpensive and suitablefor disposable use. Moreover, they can easily wipe off fine dust.However, the cleaning articles per se are so flat that the capability oftrapping relatively large dust is low.

On the other hand, disposable cleaning-articles in which a brush portionis formed of fibers are also known in the art. However, since the brushportion is formed only of fibers, the rigidity of the brush portion islowered. Therefore, the fibers are entangled or curled during thecleaning operation. As a result, the portion to function substantiallyas the brush portion is compressed to cause a defect that the dusttrapping effect of the fibers cannot be sufficiently exhibited.

SUMMARY OF THE INVENTION

The present invention has an object to provide a cleaning article whichis provided with a brush portion having a high dust collecting abilityand a high shape retention and which can be manufactured at a low cost.

According to a first aspect of the invention, there is provided acleaning article comprising a brush portion including: a plurality ofstrips; and at least one layer of a fiber bundle.

This cleaning article can trap fine dust with its fiber bundle layerforming the brush portion, while suppressing the entanglement of thefibers with the strips. In addition, the strips per se can exhibit thecleaning effect. With the strips, moreover, the brush portion is soincreased in rigidity as to have a high shape retention against anexternal force.

For example, this cleaning article may be constructed such that at leastone sheet having the plurality of strips formed therein and the fiberbundle layer are stacked on and partially joined to a base material. Ifthey are thus joined, disaggregation or entanglement of fibers formingthe fiber bundle layer can be suppressed so that the dust trappingability of the brush portion is also enhanced at its face adjacent tothe base material.

The base material may be a sheet formed with strips. This can enhancethe contact with the object to be cleaned, which may have varioussurface shapes, so that the dust trapping ability can be furtherimproved.

The cleaning article according to the first aspect of the invention maybe constructed such that the sheet appears on the outermost face of thecleaning article on its cleaning side. In this construction, since thestrips having a relatively high rigidity are positioned on the outermostface, there hardly occurs a phenomenon that fibers of the fiber bundlelayer are entangled and fixed during the cleaning operation, so that thecleaning article can stand the use of a long term.

Alternatively, the fiber bundle layer may appear on the outermost faceof the cleaning article on its cleaning side, in place of the secondarysheet. In this construction, the fiber bundle layer can conform to thefine irregularities of the object to be cleaned, to thereby have animproved contact. Therefore, the fine dust trapping ability can beimproved.

Here, it is preferred that fibers of the fiber bundle layer are fixed toone another over a predetermined length from a portion where the fiberbundle layer is joined to the base material. With the fibers of thefiber bundle layer being fixed to one another over a predeterminedlength from the joining portion, even if the fiber bundle layer appearson the outermost face, the fibers of the fiber bundle layer can beprevented from being entangle or massed by the friction during thecleaning operation.

It is also possible that another fiber bundle layer is provided suchthat one fiber bundle layer closer to the base material has a basisweight larger than that of the other fiber bundle layer closer to theoutermost face of the cleaning article on its cleaning side. In thisconstruction, the base material can be prevented during the cleaningoperation from being exposed on the cleaning side of the cleaningarticle. In addition, the cleaning article can provide a sufficientcushioning feel during the cleaning operation.

Preferably, the base material is provided on its outer face opposed tothe cleaning face with a holding sheet. In this construction, forexample, between the outer face of the base material and the holdingsheet, there may be formed a holding space into which a hand of a useror a holder is enabled to be inserted.

Moreover, the fiber bundle layer may be joined to the base material attwo sides of the holding space extending in a direction along which thehand or holder is permitted to be inserted. In this construction, theobject to be cleaned is not affected by the hardness of the holder sothat the cleaning article provides a smooth contact feel when used forcleaning operation.

According to a second aspect of the invention, there is provided acleaning article comprising: at least two sheets, at least one of whichhas a plurality of strips; and at least two layers of a fiber bundle,wherein the two sheets are overlaid and joined to each other at twojoining portions, which define a holding space between the confrontingfaces of the two sheets, and the two fiber bundle layers are disposed onthe cleaning faces, respectively, of the two sheets, and are joinedthereto at the two joining portions.

The cleaning article according to the second aspect of the invention canexhibit the cleaning function on both its surface and back. Therefore,it can be used for cleaning operation without any attention to itscleaning side. Moreover, since the cleaning article can be used forcleaning operation firstly with one face and then with the other face, along life is allowed.

In this construction, too, it is possible that the strips and the fiberbundle layers form a brush portion. Therefore, the cleaning article cantrap fine dust while suppressing entanglement of fibers. In addition,the strips per se can exhibit the cleaning effect.

Here, it is possible that some of fibers of the fiber bundle layer arenot extended continuously between the two joining portions so as to formfiber brush portions, each extending from one of the two joiningportions and having a free end. These fiber brush portions can exhibitdust wiping function to thereby improve the cleaning ability.

For example, the two sheets and the fiber bundle layers may further bejoined to one another midway between the two joining portions to dividethe holding space into two parallel holding spaces, and the fiberextending direction in the fiber bundle layers may traverse the twoholding spaces. In this construction, these holding spaces arepreferably opened at their two opposite ends for insertion of theholder.

In the foregoing individual constructions, it is preferred that thefiber bundle layer is partially joined to adjacent strips, at midwaypositions of the adjacent strips. With this construction, the fiberbundle layer moves together with the strips so that the fiber bundlelayer can be prevented from moving independently to have its fibersentangled or massed.

Moreover, it is preferred that a sheet for forming the strips is formedof either a nonwoven fabric comprising thermoplastic fibers or athermoplastic resin film. Also, it is preferred that the fiber bundlecomprises heat-fusible thermoplastic fibers. Here, the sheet having thestrips and the fiber bundle layer can be joined to each other easily andquickly by heat-fusing. Especially if the thermoplastic fibers are usedfor forming the sheet, the nonwoven fabric can be manufactured by athrough-air bonding process to have a high rigidity and elasticity.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a cleaning article according to afirst embodiment of the invention;

FIG. 2 is a partially enlarged perspective view showing a brush portionof the cleaning article of FIG. 1;

FIG. 3 is a perspective view showing the cleaning article of FIG. 1 fromthe back side;

FIGS. 4A and 4B are perspective views showing a base sheet of thecleaning article of FIG. 1 and a laminate of the base sheet and a firstfiber bundle layer, respectively;

FIG. 5 is a perspective view showing a laminate of a second fiber bundlelayer and a secondary sheet of the cleaning article of FIG. 1;

FIG. 6 is a perspective view showing a modification of the cleaningarticle of the first embodiment;

FIG. 7 is a perspective view showing a cleaning article according to asecond embodiment of the invention;

FIG. 8 is a sectional view of the cleaning article of FIG. 7; and

FIG. 9 is a perspective view showing a modification of the cleaningarticle of the second embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As used herein, the term “cleaning article” refers to devices having abrush portion, which are intended to be used for cleaning or sweepingpurposes.

As used herein, the term “cleaning face/cleaning side” refers tofaces/sides, which are intended to be directed to the object to becleaned or swept in use.

As used herein, the term “strip” refers to a long narrow piece of asheet.

As used herein, the term “fiber bundle” refers to a bundle of a numberof fibers. Examples of the fibers include filaments, flat yarns, splityarns and the like. Unless otherwise noted, these fibers are notheat-fused to one another in the fiber bundle.

FIG. 1 is a perspective view showing a cleaning article according to afirst embodiment of the invention and taken from the side of a cleaningface; FIG. 2 is a perspective view showing a portion of a brush portionof the cleaning article of FIG. 1 in an enlarged scale; FIG. 3 is aperspective view showing the cleaning article of FIG. 1 from the backside; FIGS. 4A and 4B and FIG. 5 are perspective views showing thecleaning article of FIG. 1 separately of layers; and FIG. 6 is aperspective view showing another layer structure of a cleaning article.

In FIGS. 1 and 2, a cleaning article 1 according to a first embodimentof the invention is shown with its cleaning side upward. The cleaningarticle 1 comprises a primary sheet (or base sheet) 2, and a first fiberbundle layer 3, a second fiber bundle layer 4, a secondary sheet 5having strips formed therein, and a third fiber bundle layer 6 laminatedsubsequently upward on the cleaning face of the base sheet 2. Theshorter sides of the cleaning article 1 extend parallel to the feedingdirection (or MD) along which materials for the above-mentioned layersare continuously fed on the production line. These individual layers(i.e., the base sheet 2, the first fiber bundle layer 3, the secondfiber bundle layer 4, the secondary sheet 5 and the third fiber bundlelayer 6) are joined altogether at an all-layer joining line 7 extendingperpendicularly to MD.

In the embodiment shown, the base sheet 2 and the sheet 5 areindividually formed of a nonwoven fabric formed only of or containingthermoplastic fibers (i.e., heat-fusible fibers). Examples of thethermoplastic fibers include: fibers of PE (polyethylene), PP(polypropylene) or PET (polyethylene terephthalate); and conjugatedfibers of PE/PET or PE/PP (e.g., conjugated fibers of a core/sheathstructure having a core of PP or PET and a sheath of PE). The nonwovenfabric may be a thermal bonded nonwoven fabric, a spun-bonded nonwovenfabric or a spun-laced nonwoven fabric. Alternatively, the base sheet 2and the sheet 5 may be formed of a thermoplastic resin film such as a PEfilm or a PP film. Of course, it is also possible that the base sheet 2and the sheet 5 are formed of a laminated sheet of a nonwoven fabric anda resin film.

In order to increase the rigidity and elasticity, it is preferred thatthe base sheet 2 and the sheet 5 are formed of a through-air bondednonwoven fabric in which the thermoplastic fibers are bonded with heatedair. Especially where the sheet 5 is disposed to form the outermost faceof the cleaning article on the cleaning side (See FIG. 6), it isdesirable that the sheet 5 is formed of a through-air bonded nonwovenfabric.

In the embodiment shown, the first fiber bundle layer 3, the secondfiber bundle layer 4 and the third fiber bundle layer 6 individuallycomprise a bundle of thermoplastic filaments. These individual filamentsextend continuously to traverse each fiber bundle layer. Such a fiberbundle layer can be easily formed by opening a tow of filaments. Morespecifically, each fiber bundle layer can be formed over a sheet by thefollowing steps of: opening a tow of filaments to have a predeterminedwidth and a predetermined thickness (or bulk), while being fedcontinuously in MD; joining the opened tow onto a continuously fed sheetmaterial; and cutting the tow together with the sheet material at aninterval (corresponding to the size of the cleaning article in MD). Thefilaments may be made of any suitable materials such as PE, PP, PET, Ne(nylon), rayon, or combination thereof. Preferably, the filaments areconjugated fibers of a core/sheath structure having a core of PP or PETand a sheath of PE.

The filaments are preferred to have a fineness of 1 to 50 dtex, morepreferably 2 to 10 dtex. Here, the individual fiber bundle layers maycontain fibers of different finenesses.

However, the fibers forming the fiber bundle layer of the inventionshould not be limited to the filaments. For the fiber bundle layer, flatyarns or split yarns may also be employed. The flat yarns are preparedby slitting a film into tapes and by stretching the tapes in thelongitudinal direction. The split yarns are prepared by splitting athermoplastic film in the direction perpendicular to the orientationdirection of the resin so that the film is fibrillated andinterconnected into a net shape.

Preferably, the fibers forming the fiber bundle layer of the inventionare crimped. With the fibers being crimped, the fiber bundle layerbecomes so bulky as to take a structure enabled to capture dust easilyby the crimped portions. Especially preferred are crimped filamentsopened from a tow.

Here will be described the structures of the individual layers formingthe cleaning article 1 and the procedure for laminating the layers.

FIG. 4A shows the base sheet 2 which is formed of a spun-bonded nonwovenfabric, a through-air bonded nonwoven fabric, or the like. The basesheet 2 has a central region 2 a, and strip-forming regions 2 b and 2 blying opposite one another and sandwiching the central region 2 atherebetween. On the other hand, FIG. 3 shows the base sheet 2 with itsback face 2B upward. Over the back face 2B, there is laid a holdingsheet 8 extending from-the central region 2 a to the strip-formingregions 2 b and 2 b. In the embodiment shown, the holding sheet 8 isformed, like the base sheet 2, of a nonwoven fabric such as aspun-bonded nonwoven fabric, a through-air bonded nonwoven fabric, orthe like. However, the holding sheet 8 may be formed of a resin film.The base sheet 2 and the holding sheet 8 are identical in their sizes inMD, but not identical in their sizes in the direction perpendicular toMD. The holding sheet 8 is shorter than the base sheet 2 in thedirection perpendicular to MD.

With the holding sheet 8 being laid over the outer face 2B of the basesheet 2, cut lines 11 in a zigzag shape (or in a saw-tooth shape) arecut in the strip-forming regions 2 b and 2 b, to form a plurality ofstrips 12, which are separated from one another by the cut lines 11 andelongated in MD, in the base sheet 2 and the holding sheet 8.

Over a cleaning face 2A of the base sheet 2 having the strips 12, asshown in FIG. 4B, there is laid the first fiber bundle layer 3. At thistime, the individual filaments forming the first fiber bundle layer 3extend in MD, and the first fiber bundle layer 3 has a predeterminedbulk over the cleaning face 2A of the base sheet 2.

In such a laminated state, the base sheet 2, the holding sheet 8disposed on the outer face 2B, and the first fiber bundle layer 3disposed on the cleaning face 2A are joined together at joining lines 13and 13 and joining lines 14 and 14. Here, the joining is performed byheat-sealing, ultrasonic sealing or the like, so that the base sheet 2,holding sheet 8 and the first fiber bundle layer 3 are fusion-bonded atthe joining lines 13 and 14.

The paired joining lines 13, 13 are formed along the boundary linesbetween the central region 2 a and the strip-forming regions 2 b and 2b, so that they extend parallel with one another while being spaced inMD. On the other hand, the joining lines 14, 14 are formed in a zigzagshape (or in a saw-tooth shape) in the strip-forming regions 2 b and 2b, respectively.

As a result, as shown in FIG. 2 in an enlarged scale, the individualfilaments forming the first fiber bundle layer 3 are joined to theunderlying strips 12 at the joining lines 14 extending obliquelytransversely over the strips 12 at midway areas between theirlongitudinal ends. With the joining lines 14, motions of the individualfilaments can be restrained so properly that the filaments are preventedfrom being excessively separated or entangled, while being enabled tomove over the strips 12 relatively freely, to thereby exhibit anexcellent dust collecting effect.

FIG. 5 shows the state in which the second fiber bundle layer 4 and thesheet 5 are laminated.

The sheet 5 is formed of a spun-bonded or through-air bonded nonwovenfabric, like the base sheet 2, or a resin film. The sheet 5 has the samesize and shape as those of the base sheet 2, except for those of stripsformed therein.

The sheet 5 has a central region 5 a and strip-forming regions 5 b and 5b lying opposite one another and sandwiching the central region 5 atherebetween. These strip-forming regions 5 b and 5 b are cut to form aplurality of cut lines 16 extending in a zigzag shape (or in a saw-toothshape) from the longer side edges of the sheet 5 toward the centralportion 5 a in MD. Thus, there are formed a plurality of strips 17 whichare separated by the cut lines 16 and elongated in MD.

If the strips 12 of the base sheet 2 shown in FIG. 4A have a length L1and a width W1 and if the strips 17 of the sheet 5 shown in FIG. 5 havea length L2 and a width W2, L2>L1 and W1>W2 so that the strips 17 arethinner and longer than the strips 12. Here, the individual strips 12and 17 are formed to have widths of at least 2 mm, preferably widths of2 to 50 mm and lengths of 10 to 100 mm.

The second fiber bundle layer 4 is laminated on the back face 5B of thesheet 5. In the manufacture process, the back face 5B of the sheet 5 isdirected upward, and the second fiber bundle layer 4 is laid over theback face 5B. At this time, the individual filaments forming the secondfiber bundle layer 4 extend in MD, and the second fiber bundle layer 4has a predetermined bulk over the back face 5B of the sheet 5.

In such a laminated state, the strips 17 and the second fiber bundlelayer 4 are joined-together at joining portions 18 which are positionedmidway between longitudinal ends of the strips 17. At these joiningportions 18, specifically, the strips 17 and the second fiber bundlelayer 4 are fusion-bonded by heat-sealing or ultrasonic sealing. Asshown in FIG. 5, the joining portions 18 are formed alternately in everyothers of strips 17 which are arranged in the direction perpendicular toMD. In other words, the strips 17 with and without the joining portions18 alternate with each other. However, all the strips 17 may have thejoining portions 18.

As shown in a partially enlarged view of FIG. 2, the second fiber bundlelayer 4 is joined to the overlying strips 17 at the joining portions 18positioned midway between the longitudinal ends of the strips 17.Therefore, the second fiber bundle layer 4 is retained in its shape bythe strips 17 so that the filaments forming the second fiber bundlelayer 4 are prevented from being excessively entangled or curled.

At the final stage of the manufacture process of the cleaning article 1,over the first laminate in which the base sheet 2, the holding sheet 8and the first fiber bundle layer 3 are laminated and joined, as shown inFIG. 4B, there is laid the second laminate in which the second fiberbundle layer 4 and the sheet 5 are laminated and joined, as shown inFIG. 5. At this lamination, the first and second laminates are laid suchthat the second fiber bundle layer 4 lies over the first fiber bundlelayer 3.

Over the cleaning face 5A of the sheet 5 of the second laminate,moreover, there is laid the third fiber bundle layer 6, as shown inFIG. 1. The individual filaments forming the third fiber bundle layer 6extend in MD, and the third fiber bundle layer 6 has a substantiallyhomogeneous bulk over the cleaning face 5A of the sheet 5. Then, theholding sheet 8, the base sheet 2, the first fiber bundle layer 3, thesecond fiber bundle layer 4, the sheet 5 and the third fiber bundlelayer 6 are joined altogether into an integral structure at theall-layer joining line 7 which extends in MD along the center line ofthe cleaning article 1. This all-layer joining line 7 is a fusing sealline by heat sealing, ultrasonic sealing or the like, so that theindividual layers are fusion-bonded at the all-layer joining line 7 tobe integrated altogether.

As shown in FIGS. 1 and 2, the cleaning article 1 thus constructed hasbrush portions 26 at right and left sides on the cleaning face 2A of thebase sheet 2. These brush portions 26 are formed by an assembly of thestrips 12 of the base sheet 2, the first fiber bundle layer 3, thesecond fiber bundle layer 4, the strips 17 of the sheet 5 and the thirdfiber bundle layer 6.

When the floor, furniture, or the like is wiped with the cleaning sideof the cleaning article 1, which is shown upward in FIG. 1, fine dustcan be collected by the third fiber bundle layer 6 appearing on theoutermost face of the cleaning article 1, and by the first and secondfiber bundle layers 3 and 4 inside of the brush portions 26. Here, thestrips 12 and 17 exhibit the function to wipe off the dust, and thedust, as wiped off by the strips 12 and 17, can also be trapped by thefiber bundle layers 3, 4 and 6.

In this embodiment, the strips 17 are interposed between the secondfiber bundle layer 4 and the third fiber bundle layer 6. When thecleaning operations are repeated, therefore, the filaments of the secondfiber bundle layer 4 and the filaments of the third fiber bundle layer 6are prevented from being excessively entangled, so that the shape of thebrush portions 26 can be retained for a long term.

Moreover, the filaments of the first fiber bundle layer 3 and thefilaments of the second fiber bundle layer 4 are partially joined to thestrips 12 and the strips 17, respectively, so that they are preventedfrom being excessively curled or entangled. Even after a cleaningoperation for a long period, therefore, the brush portions 26 are hardlycrushed so that they are excellent in the shape retention.

On the outer face side of the cleaning article 1 thus completed, asshown in FIG. 3, the base sheet 2 and the holding sheet 8, which arefirstly joined at the joining lines 13 and 13, are further joined at theall-layer joining line 17 which is formed midway between the joininglines 13 and 13. In the holding region on the outer face of the centralregion 2 a, therefore, there are formed two parallel holding spaces 20and 20, each of which is defined between one of the joining lines 13 andthe all-layer joining line 7.

Therefore, the cleaning article 1 can be held from the outer face sideby a holder 21 of a bifurcated structure, as shown in FIG. 3. Thisholder 21 includes bifurcated insert portions 22 and 22 and a gripportion 23. The insert portions 22 and 22 are inserted into the holdingspaces 20 and 20. Thus, the cleaning operation can be performed byholding the grip portion 23.

It is possible to adopt a variety of structures for preventing thecleaning article 1 from easily coming out of the holder 21 at thecleaning time.

First, the insert portions 22 and 22 may be formed on their lower faceswith a number of saw-tooth shaped protrusions 22 a, which are arrangedfinely with sharp edges. With the protrusions 22 a being directed towardthe base sheet 2, the insert portions 22 and 22 are inserted into theholding spaces 20 and 20. In this inserted state, the saw-tooth shapedprotrusions 22 a and the base sheet 2 are retained in a high coefficientof friction so that they can prevent the cleaning article 1 from easilycoming out.

It is also effective to fix a retaining fastener 24 on the root endportion of the insert portions 22 and 22 of the holder 21. Thisretaining fastener 24 is formed with fine hook-shaped or mushroom-shapedprojections. With the retaining fastener 24 being retained on the backface 2B of the base sheet 2, the cleaning article 1 is prevented fromcoming out of the holder 21.

Moreover, it is also possible to provide a pivotable connect member 25to the leading end portion of one of the bifurcated insert portions 22.This connect member 25 is turned, when the insert portions 22 and 22 areinserted so far into the holding spaces 20 and 20 that their leadingends pass through and come out of the holding spaces 20 and 20, tothereby retain the connect member 25 on the leading end of the otherinsert portion 22 by engagement between concave and convex, or the like.The prevention of the cleaning article 1 from coming out of the holder21 can also be ensured by this retention.

To the holder 21, there may be provided all or at least one of the meansfor preventing the coming-out of the cleaning article 1 (i.e., all or atleast one of the protrusions 22 a, the retaining fastener 24 and theconnect member 25). Here, the holder 21 having such means can be usednot only in the cleaning article of the invention but also in anycleaning article.

The cleaning article 1 thus far described has a symmetrical shape, asshown in FIG. 3. Therefore, if the cleaning article 1 is used forcleaning operation while being attached to the holder 21 from thedirection shown in FIG. 3 and is locally soiled, the cleaning article 1may be removed from the holder 21 and turned 180 degrees from theposition shown in FIG. 3 to be attached to the holder 21 again. If thecleaning article 1 is used for cleaning operation by changing itsdirection thus described above, the individual portions of the cleaningarticle 1 can be homogeneously used without any unbalance.

Here, if the insert portions 22 of the holder 21 are formed of an easilydeformable material, it is possible to bend arbitrarily the shape of thecleaning article 1 held by the holder 21. If the grip portion 23 isgiven an extensible structure, on the other hand, the cleaning operationmay be performed while the grip portion 23 being extended long.

Here in the cleaning article 1, the first fiber bundle layer 3 is joinedto the base sheet 2 at the joining lines 13 and 13, as shown in FIG. 4B,so that the cleaning faces of the insertion portions 22 and 22 to beinserted into the holding spaces 20 and 20 are covered at any time notonly With the base sheet 2 but also with the first fiber bundle layer 3.Therefore, even if the right or left brush portion is unintentionallyturned over during cleaning operation, the first fiber bundle layer 3exists at a predetermined sufficient thickness between the object to becleaned and the insertion portions 22 and 22 of the holder 21. As aresult, the object to be cleaned is not affected by the hardness of theholder so that the cleaning article 1 provides a smooth contact feelwhen used for cleaning operation.

FIG. 6 is a perspective view showing a cleaning article 1A as amodification of the first embodiment of the invention.

The cleaning article 1A shown in FIG. 6 is prepared by changing theorder of laminations of the individual layers of the cleaning article 1shown in FIGS. 1 to 5.

In this cleaning article 1A, there is provided an outermost base sheet15 which is formed of a through-air bonded nonwoven fabric, and the basesheet 2 formed of a spun-bonded nonwoven fabric or the like is laid overthe cleaning- face of the this outermost base sheet 15. Over thecleaning face 2A of the base sheet 2, moreover, there are laid the firstfiber bundle layer 3, the second fiber bundle layer 4, the third fiberbundle layer 6 and the sheet 5 sequentially upward. The sheet 5 isformed with the strips 17 and appears on the outermost face of thecleaning article 1A on its cleaning side. The sheet 5 may be formed ofany suitable material such as a nonwoven fabric or a resin film, but ispreferably formed of a through-air bonded nonwoven fabric.

Then, the outermost base sheet 15, the base sheet 2 and the first fiberbundle layer 3 are joined to one another on the same joining lines 13and 13 as those shown in FIG. 4B. Moreover, all the layers from theoutermost base sheet 15 to the sheet 5 having the strips 17 are joinedaltogether at the same all-layer joining line 7 as that shown in FIGS. 1and 2. This all-layer joining line 7 extends along the center line ofthe cleaning article 1A.

Here, as in the structure shown in FIG. 5, the third fiber bundle layer6 and the overlying sheet 5 may be joined at the joining lines 18positioned midway between the longitudinal ends of the strips 17 so thatsome of the filaments of the third fiber bundle layer 6 are partiallyintegrated to the strips 17. Moreover, the base sheet 2 may be formedwith the plurality of strips 12, as in FIG. 4A, and the strips 12 andthe first fiber bundle layer 3 may also be joined at the zigzag joininglines 14, as in FIG. 4B.

Of course, it is also possible that the holding sheet 8 is joined to theouter face of the outermost base sheet 15, as in FIG. 3, to form theholding spaces 20 and 20 between the outermost base sheet 15 and theholding sheet 8.

In the cleaning article 1A shown in FIG. 6, the sheet 5 having thestrips 17 is provided to form the outermost face on the cleaning side sothat it abuts preferentially against the object to be cleaned, such asfloor, furniture or the like. Therefore, it is possible to prevent thefilaments of the individual underlying fiber bundle layers 3, 4 and 6from being excessively entangled or massed by the friction with theobject to be cleaned. Especially if some of the filaments of the thirdfiber bundle layer 6 are joined at the joining lines 18 to the overlyingstrips 17, they are hardly entangled or massed. If the outermost sheet 5is formed of a highly rigid and soft through-air bonded nonwoven fabric,moreover, the brush portions 26, as formed of the strips and the fiberbundle layers, are hardly deformed by the friction with the object to becleaned, so that they hardly lose their shapes even after used for along term.

When the sheet 5 having the strips 17 forms the outermost face of thecleaning article on its cleaning side, as shown in FIG. 6, it is themore preferable that the individual strips 17 are the longer. It is,therefore, preferred that the cut lines 16 for separating the strips 17are extended to or close to the all-layer joining line 7. Alternatively,it is also possible that the cut lines 16 cross the whole area of thesheet 5 in MD so that the strips 17 are completely separated from eachother before joined to the other layers at the all-layer joining line 7.

As has been described above, if the strips 17 formed of the through-airbonded nonwoven fabric are positioned on the outermost face of thecleaning article on its cleaning side, as in the embodiment shown inFIG. 6, the brush portions 26 can reliably retain their shapes evenafter use of a long term. On the other hand, if the fiber bundle layeris positioned on the outermost face of the cleaning article on itscleaning side, as in the embodiment shown in FIGS. 1 to 5, the filamentsof the fiber bundle layer are liable to be entangled or massed by thefriction with the object to be cleaned for a long term, comparatively.

In the cleaning article 1 shown in FIGS. 1 to 5, therefore, it ispreferred to apply a fixing agent to the third fiber bundle layer 6appearing on the outermost face. Examples of the fixing agent include anoil agent, a wax, and a resin such as a HMA (hot melt adhesive). Thisfixing agent thus applied can prevent freedom of movement of thefilaments (i.e., suppress disaggregation of the filaments) so that thefilaments can be prevented from being excessively entangled or massed atthe wiping time.

This fixing agent may be partially applied to the third fiber bundlelayer 6. For example, the fixing agent may be sprayed exclusively to thecleaning face of the third fiber bundle layer 6 thereby to fix thefilaments appearing on the cleaning face of the third fiber bundle layer6 exclusively. Alternatively, the fixing agent may be applied to thethird fiber bundle layer 6 over a predetermined length from theall-layer joining line 7 so that the filaments forming the third fiberbundle layer 6 remain free on the side of their free ends. In bothcases, the filaments forming the third fiber bundle layer 6 can beprevented from being excessively entangled, without lowering the dusttrapping effect by the fiber bundle layer 6. Preferably, the fixingagent is solid at the room temperature.

In the case where a wax is used for fixing, for example, the ratio ofthe wax to the fiber bundle layer 6 is preferably from 0.5 to 25% byweight. If the ratio is less than 0.5% by weight, the entanglement ofthe filaments could not be prevented effectively. If more than 25% byweight, on the other hand, the filaments will be excessively firmlyfixed. Therefore, since the filaments can not be sufficiently raised,the dust trapping effect is lowered.

In the case where a HMA is used for fixing, this HMA is preferred tohave a low viscosity. If a HMA having a high viscosity is used, dusttrapping property is enhanced but the filaments are liable to beentangled. Of course, the fixing agent may be prepared by mixing a waxand a HMA having a low viscosity.

Here, the entanglement of the filaments may be prevented not by themethod of applying the fixing agent to the fiber bundle layer 6 but bysolidifying the filaments of the fiber bundle layer 6 again aftermelting them with a solvent or by a heat. In this case, too, it ispossible to firmly fix the filaments of the fiber bundle layer 6 only atthe side of the all-layer joining line 7 to prevent the entanglement,while leaving the degree of freedom at the side of their leading ends sothat the filament can be raised easily.

Of course, the fixing of filaments in each fiber bundle layer should notbe limited to the cleaning article 1. For example, also in the cleaningarticle 1A shown in FIG. 6, the filaments in the individual fiber bundlelayers 4 and 6 may be fixed to one another with a fixing agent or byfusing them, as has been described above.

In the cleaning article 1 shown in FIG. 1, the third fiber bundle layer6 is joined to the other layers only at the all-layer joining line 7.However, it is also possible to form other joining lines spaced apartfrom the all-layer joining line 7 to thereby join the third fiber bundlelayer 6 only to the underlying sheet 5 or to all the other layers (i.e.,from the sheet 5 to the base sheet 2). This can also prevent thefilaments of the third fiber bundle layer 6 from being excessivelyentangled or massed.

In both the cleaning article 1 shown in FIG. 1 and the cleaning article1A shown in FIG. 6, it is preferable that the basis weight of the firstfiber bundle layer 3 the closest to the base sheet 2 is larger thanthose of the overlying second fiber bundle layer 4 and third fiberbundle layer 6. In such a construction, even if the strips or thefilaments forming the brush portions 26 are entangled or massed byrepeating the cleaning operations for a long term, the base sheet 2 isnot exposed from the brush portions 26. Therefore, the base sheet 2 canbe prevented from coming into direct contact with the object to becleaned.

FIG. 7 is a perspective view showing a portion of a cleaning article 30according to a second embodiment of the invention, and FIG. 8 is asectional view of the cleaning article 30.

The cleaning article 30 comprises sheets 31 and 32 formed of a nonwovenfabric or the like, and fiber bundle layers 33 and 34. The sheet 31 hasa plurality of strips 31 a formed on its two side portions and elongatedin MD. The sheet 32 laid over the sheet 31 also has a plurality ofstrips 32 a formed on its two side portions. These strips 31 a and 32 aare formed by forming a plurality of cut lines in the two side portionsof the individual sheets 31 and 32.

The fiber bundle layer 33 is disposed on the lower face (cleaning face)of the sheet 31; and the fiber bundle layer 34 is disposed on the upperface (cleaning face) of the sheet 32. The sheets 31 and 32 and the fiberbundle layers 33 and 34 thus laminated are integrally fusion-bonded at acenter joining line 35 and side joining lines 36 and 36. On the outerside portions beyond the side joining lines 36 and 36, there are formedbrush portions 37 and 37 of assemblies of the strips 31 a and 32 a andthe fiber bundle layers 33 and 34.

The two side joining lines 36 and 36 define a holding region 38therebetween. In the holding region 38, two holding spaces 39 and 39separated by the center joining line 35 are formed between the sheet 31and the sheet 32. Into those holding spaces 39 and 39, there can beinserted the insert portions 22 and 22 of the holder 21 shown in FIG. 3.Alternatively, a relatively wide, single holding space may be formedbetween the side joining lines 36 and 36 without providing the centerjoining line 35. Here, the holder to be inserted into the wide holdingspace may be given a flat shape.

In the holding region 38, moreover, there are formed cut lines 41 eachextending in the direction perpendicular to MD. Midway between adjacentjoining lines 35 and 36, these cut lines 41 are arranged intermittentlyat a predetermined spacing. The sheets 31 and 32 and the fiber bundlelayers 33 and 34 are cut altogether at those cut lines 41.

As a result, on both the upper and lower faces (i.e., two cleaningfaces) of the cleaning article 30, filaments crossing the cut lines 41are cut in the holding region 38, thereby to form fiber brush portions42 extending from the joining lines 35 and 36. On the other hand,filaments not crossing the cut lines 41 remain uncut in the holdingregion 38, thereby to form fiber bridges 43 extending between adjacentjoining lines 35 and 36. These fiber brush portions 42 and fiber bridges43 are alternated in the direction perpendicular to MD.

In this cleaning article 30, the brush portions 37 and 37 on its twoside portions are the assemblies of the fiber bundle layers 33 and 34and the strips 31 a and 32 a. Therefore, the brush portions 37 have suchhigh overall rigidities that the strips 31 a and 32 a can wipe off thedust whereas the fiber bundle layers 33 and 34 can trap the dust.

In the holding region 38, on the other hand, the fiber brush portions42, as formed by cutting the fiber bundle layers 33 and 34 at the cutlines 41, can exhibit the function to wipe off the dust, and the fiberbridges 43 can trap the dust wiped off. Therefore, the cleaning article30 can exhibit the cleaning function not only at the brush portions 37and 37 but also at both the upper and lower faces in the holding region38, so that it can perform an effective cleaning operation at anyportions.

As shown in FIG. 8, it is also possible to provide other layers 44 and45 between the sheet 31 and the fiber bundle layer 33 having the fiberbrush portions 42 and between the sheet 32 and the fiber bundle layer 34having the fiber brush portions 42, respectively. These layers 44 and 45are not cut at the cut lines 41 and may be formed of a fiber bundlehaving a large basis weight or a through-air bonded nonwoven fabric.

FIG. 9 is a perspective view showing a cleaning article 50 according toa third embodiment of the invention.

In this cleaning article 50, two side portions of a sheet 51 are cut ata plurality of cut lines to form a plurality of strips 51 a, and twoside portions of a sheet 52 are cut likewise to form a plurality ofstrips 52 a. On the lower face of the sheet 51, there is disposed afiber bundle layer 53, and on the upper face of the sheet 52, there isdisposed a fiber bundle layer 54. The sheet 51, the sheet 52, the fiberbundle layer 53 and the fiber bundle layer 54 are integrallyfusion-bonded at joining lines 55 and 56 extending in parallel.

On the two side portions beyond the joining lines 55 and 56, there areformed brush portions 57 of assemblies of the strips 51 a, the strips 52a, the fiber bundle layer 53 and the fiber bundle layer 54.

The joining line 55 and the joining line 56 define a holding spacebetween the sheet 51 and the sheet 52. Into this holding space, there isinserted a holder 61. At this time, if the cleaning article 50 isattached to the holder 61 while being twisted, the brush portions 57 canbe deformed to extend helically.

In this cleaning article 50, the brush portions 57 are directed in alldirections around the holder 61. Therefore, the cleaning article 50 caneffectively trap dust when used to clean a narrow gap or the like.

Here, the embodiment of FIG. 7 may be given a structure in which a fiberbundle layer is further clamped between the strips 31 a of the sheet 31and the strips 32 a of the sheet 32. Likewise, the embodiment shown inFIG. 9 may also be given a structure in which a fiber bundle layer isfurther clamped between the strips 51 a of the sheet 51 and the strips52 a of the sheet 52.

In the embodiments of FIGS. 7 and 9, moreover, the strips and the fiberbundle layers may be partially joined to one another midway between thelongitudinal ends of the strips.

In the foregoing individual embodiments, if the fiber bundle layers areformed of crimped fibers, the fibers themselves can trap the dusteasily. If the fibers (e.g., filaments opened from a tow or split yarns)are joined to the sheet while being stretched in MD, and are then cuttogether with the sheet, moreover, the fibers are crimped so that theportions of the fiber bundle layer forming the brush portions becomeshorter than the strips. In this construction, it is possible to enhanceboth the dust trapping function by the crimped fibers and the dustwiping function by the strips extending beyond the free ends of thecrimped fibers, so that the cleaning function can be effectivelyexhibited by the assembly of the fibers and the strips.

Moreover, the dust adsorbing and trapping effect can be enhanced byapplying a dust-adsorbing agent to the fiber bundle layers and/or thestrips. This dust-adsorbing agent is exemplified by a surface-activeagent, mineral oil or wax. It is also possible to apply an acrylicadhesive or a hot melt adhesive which has a weakened adhesion.

The fiber bundle layers and/or the strips may further contain asubstance such as a deodorant, a humectant or an anti-fungus agent inaddition-to the dust-adsorbing agent.

If the sheets in the individual embodiments are given an elasticstretchability between the joining lines formed in the holding region,moreover, the sheets can make close contact with the holder when thecleaning article is attached to the holder, so that the cleaning articlehardly comes out of the holder.

In the individual embodiments, the nonwoven fabric to be used to formthe sheets having the strips should not be limited to one formed by thespun-bonding process or the through-air bonding process, but may beformed by the thermal bonding, spun-lacing, point-bonding, melt-blowing,stitch bonding, chemical bonding, needle punching or the like. Moreover,the nonwoven fabric may be replaced by a material to be worked into thestrips, such as urethane, sponge, a woven fabric, a net or a splitcloth.

Where the sheets having the strips are formed of a nonwoven fabric, thenonwoven fabric is preferred to have a basis weight of 10 to 100 g/m²and a thickness of 0.5 to 5 mm, from the point of view of handleabilitywhen combined with the fiber bundle layers and from the point of view ofprocessing technique. Moreover, the nonwoven fabric is preferred to havea width of 80 to 250 mm in MD.

As has been described above, the cleaning article of the invention has abrush portion formed of strips and a fiber bundle layer, so that thefibers of the fiber bundle layer can be prevented from being excessivelyentangled or curled, thereby to enhance the shape retention of the brushportion. Especially, if the strips and the fiber bundle layer arepartially joined to one another, the fiber bundle layer forming thebrush portion can be enhanced in rigidity and can be prevented frombeing curled or shrunken even after use of a long term.

Although various exemplary embodiments have been shown and described,the invention is not limited to the embodiments shown. Therefore, thescope of the invention is intended to be limited solely by the scope ofthe claims that follow.

1-17. (canceled)
 18. A cleaning article comprising: a fusible sheet; aplurality of cut lines extending in a zigzag shape inward from an edgeof the base sheet; a plurality of strips formed between adjacent cutlines; a fiber bundle layer including fusible fibers at least in part,wherein the fiber bundle layer is laid on the sheet, the sheet and thefiber bundle layer being fusion-bonded to each other along a joiningline crossing the fiber of the fiber bundle layer; a brush portiondefined by the strips and the fiber bundle layer extending outward fromthe joining lines.